12/2008 WIRE ROPE INSTALLATION GUIDE 08 - Python

1 WIREROPEINSTALLATIONGUIDEFORMOBILECRANES 0812/ 2008 QuickInstallationGuideforMobileCranes -2-UseandCareofWireRopeSomeThingsEveryUs erShouldKnowAboutUseandCareofWireRopeWha t follows is a brief outline of the basic information required to safely use wire rope1. wire rope WILL FAIL IF WORN OUT, OVERLOADED,MISUSED, DAMAGED, or IMPROPERLY In service, wire rope loses strength and work capability. Abuseand misuse increase the rate of The MINIMUM BREAKING STRENGTH of wire rope appliesONLY to a NEW, UNUSED The Minimum Breaking Strength should be considered thestraight line pull with both rope ends fixed to prevent rotation,which will ACTUALLY BREAK a new, UNUSED, rope . TheMinimum Breaking Strength of a rope should NEVER BEUSED AS ITS WORKING To determine the working load of a wire rope , the MINIMUM orNOMINAL Breaking Strength MUST BE REDUCED by aDESIGN FACTOR (formerly called a Safety Factor).

2 TheDesign Factor will vary depending upon the type of machineand INSTALLATION , and the work performed. YOU must determinethe applicable Design Factor for your example, a Design Factor of 5" means that the Minimum-or Nominal Breaking Strength of the wire rope must beDIVIDED BY FIVE to determine the maximum load that can beapplied to the rope Factors have been established by DIN, ISO, CEN,OSHA, ANSI, ASME and similar government and wire rope should ever be installed or used without fullknowledge and consideration of the Design Factor for wire rope WEAR OUT. The strength of a wire rope slightlyincreases after the break in period, but will decrease over approaching the finite fatigue life span the breakingstrength will sharply decrease.

3 Never evaluate the remainingfatigue life of a wire rope by testing a portion of a rope todestruction only. An indepth rope inspection must be part ofsuch NEVER overload a wire rope . This means NEVER use the ropewhere the load applied is greater than the working loaddetermined by dividing the Minimum Breaking Strength of therope by the appropriate Design NEVER SHOCK LOAD a wire rope . A sudden application offorce or load can cause both visible external damage ( ) and internal damage. There is no practical way toestimate the force applied by shock loading a rope . Thesudden release of a load can also damage a wire Lubricant is applied to the wires and strands of a wire ropewhen manufactured.

4 This lubricant is depleted when the ropeis in service and should be replaced Regular, periodic INSPECTIONS of the wire rope , and keepingof PERMANENT RECORDS SIGNED BY A QUALIFIEDPERSON, are required by OSHA and other regulatory bodiesfor almost every rope INSTALLATION . The purpose of inspection isto determine whether or not a wire rope may continue to besafely used on that application. Inspection criteria, includingnumber and location of broken wires, wear and elongation,have been established by DIN, ISO, CEN, OSHA, ANSI,ASME and other IN DOUBT, REPLACE THE When a wire rope has been removed from service because itis no longer suitable, IT MUST NOT BE RE-USED ONANOTHER Every wire rope user should be aware of the fact that eachtype of fitting attached to a wire rope has a specific efficiencyrating which can reduce the working load of a rope assemblyor rope system, and this must be given due consideration indetermining the capacity of a wire rope Some conditions that can lead to problems in a wire ropesystem include.

5 Sheaves that are too small, worn or corrugated can causedamage to wire rope . Broken wires mean a loss of strength. Kinks permanently damage a wire rope . Environmental factors such as corrosive conditions andheat can damage a wire rope . Lack of lubrication can significantly shorten the usefulservice life of a wire rope Contact with electrical wire and the resulting arcing willdamage a wire ropeThe above is the partially rewritten publication wire rope AND SLING SAFETY BULLETIN . Some of it s content was adapted to our specificrequirement and does not truly reflect the original as published by the wire rope TECHNICAL -3-InstallationofWireRopeForewordIn order to fully achieve the service life potential of Python and standard wire rope for demanding crane jobs these step bystep instructions should be followed.

6 They are intended toprevent rope damage caused by kinks, untwisting, and loosestrands, during handling and realize that the real world is not perfect. This applies alsoto wire rope INSTALLATION . It is impossible tocover ALL imaginable INSTALLATION situations, location difficulties,and crane set ups. You will also find that these instructions arenot very different from the INSTALLATION procedure of 6-strand or19x7 ropes. Many experienced Riggers may find some of thefollowing old hat . If you notice any omissions or have ideas thatwe can incorporate into this brochure we will be attaching 3 hose clamps on eitherside of the cut mark, blade cut the not use a grinding wheel but a steelcutting blade; # , you do not need to re-cut a wire rope .

7 However, youmay encounter situations where it becomes necessary to shortenthe cutting any wire rope special care MUST be taken inseizing the rope methods are suggested:1) Seizing the rope end with soft iron ) Seizing the rope end with hose cutting the rope it is good practice to braze or weld therope ends to ensure that they don t unravel. Leave the seizing onthe rope for added holding strength. Be careful not to damage theseizing while a rope with a torch may result in both uneven endsand damage to the seizing causing the strands to open diameter up to 14 mm (9/16") may be cut with a FELCOC16 hand bladecutting mountupright in a viceCarefully melt and fuse together allindividual fused wire rope end.

8 If notdamaged during the fusing procedureclamps shall be left attached to the hose clamps got damaged or are toobulky for the INSTALLATION you need toreplace all 3 of them with a wire comparison, these are factory fusedand tapered ends done with aspecialized -4-UnreelingofWireRopeWhen removing the rope from the shipping reel or coil, thereel or coil MUST rotate as the rope unwinds. Any attempt tounwind a rope from stationary reel or coil WILL result in a kinkedrope that is ruined beyond following illustrations demonstrate the right and wrongway of unreeling a care must be takennotto drag the rope overobstacles, over a deflection shaft, or around large fleet angles between the shipping reel and thefirst sheave.

9 The rope may roll in the sheave causing the ropeto unlay. This is particularly important for all DoPar-, langs lay,and non-rotating rope reeving the rope through small deflection sheavesand avoid changing the plane from vertical to you have to unspool large and heavy wire rope , use abrake to keep a slight tension on the rope . NEVER let the ropego slack and form of these precautions apply to Python as well as tostandard 6-strand-, 19x7, 19x19, and 34x7 wire in doubt, contact your nearest Unirope -5-UseofCableGripsThe most common method to install a wire rope . The typeof cable grip depends on the rope type and rope should be installed with a swivel betweenold and new ropes.

10 The old rope may have developed torqueduring it s working life and we must ensure that this torque isnot transferred to the new using cable grips,the end of the grips have tobe tightly seized on to therope body to preventaccidental slip-out of the rope . Alternately, you may wrapthe grip end with a strong reinforced industrial strengthadhesive cable grips with eye, connected to two ropes with a swivel. Use with non-rotating cable grip connected to two ropes. Most common for light cable grips with eye, connected to two ropes with a suitable length of fiber rope or a rope you start anything, make sure the diameter of the new rope youare about to install is the correct one for your that most wire ropes measure slightly over their nominaldiameter.